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PCI-100: Understanding Industrial Process Control / Level One Process Measurement & Control Fundamentals

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PCI-100 & 200


This 36 hour, 4.5 day training program uses a hands-on approach providing students with a fundamental understanding of industrial process measurement & control systems. Participants will learn the basic measurement & control principles, terminology, symbols & documentation standards. In addition students will perform hands-on exercises with actual industrial temperature, pressure, flow &level measurement & control devices to gain experience in how to set up & troubleshoot a control system.


  • Introduction to ISA documentation standards: Process Flow Diagrams (PFD’s), Piping & Instrument Diagrams (P&ID’s), Loop Diagrams, Location Plans & Installation Details
  • Test Equipment: Calibrators, Digital Multimeters & Power Supplies
  • Signals: Analog – voltage & milliamps, Digital – on/off & digital data, Wiring basics
  • Elements of a Process Control Loop: PV-Process Variable, MV-Manipulated Variable & C-Controller
  • Temperature Measurement: Thermocouples, RTDs, Thermometers, Infrared, Characteristics, Thermowell & Transmitters
  • Pressure Measurement: Gauges, Transmitters & Block & Bleed Valves
  • Flow Measurement: DP Meters, Turbine Meters, Pd Meters & Variable Area Meters
  • Level Measurement: Float Gauges, Static Head Gauges & Sounding Gauges
  • Control Valves: Types, Accessories, Sizing & Basic Troubleshooting


This is an entry level course & requires only that participants be familiar with industrial manufacturing processes.


36 Hours / 4.5 days




  • Construct a block diagram of a closed loop control system utilizing feedback.
  • List the four most common process variables found in industry.
  • List and describe the three modes of control.
  • List the units of measurement of pressure, temperature, level, and flow.
  • Convert from one unit to another.
  • List and describe the terms that are common to all closed loop feedback control systems.
  • List various methods used to measure pressure, temperature, level, and flow.
  • Determine the action of a controller to obtain if given the characteristics of the other devices in a control loop.
  • Describe the operation of the transmitters used to measure the process variables.
  • List the requirements for stability in a closed loop control system.
  • Describe the proper procedure for calibrating measurement transmitters.
  • Explain the procedures for tuning a controller using either closed loop or open loop testing.
  • Configure a microprocessor based controller to specifications given by the instructor.
  • List the three common inherent characteristics of control valves.
  • Explain the difference between inherent and installed characteristics of control valves

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